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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Frequency and Angular Variations of Land Surface Microwave Emissivities: Can we Estimate SSM/T and AMSU Emissivities from SSM/I Emissivities?

To retrieve temperature and humidity profiles from SSM/T and AMSU, it is important to quantify the contribution of the Earth surface emission. So far, no global estimates of the land surface emissivities are available at SSM/T and AMSU frequencies and scanning conditions. The land surface emissivities have been previously calculated for the globe from the SSM/I conical scanner between 19 and 85 GHz. To analyze the feasibility of deriving SSM/T and AMSU land surface emissivities from SSM/I emissivities, the spectral and angular variations of the emissivities are studied, with the help of ground-based measurements, models and satellite estimates. Up to 100 GHz, for snow and ice free areas, the SSM/T and AMSU emissivities can be derived with useful accuracy from the SSM/I emissivities- The emissivities can be linearly interpolated in frequency. Based on ground-based emissivity measurements of various surface types, a simple model is proposed to estimate SSM/T and AMSU emissivities for all zenith angles knowing only the emissivities for the vertical and horizontal polarizations at 53 deg zenith angle. The method is tested on the SSM/T-2 91.655 GHz channels. The mean difference between the SSM/T-2 and SSM/I-derived emissivities is less than or equal to 0.01 for all zenith angles with an r.m.s. difference of approx. = 0.02. Above 100 GHz, preliminary results are presented at 150 GHz, based on SSM/T-2 observations and are compared with the very few estimations available in the literature.

Prigent, Catherine↗
NASA NTRS2002

Toric offset three-reflector antenna for the advanced microwave limb sounder

An advanced Microwave Limb Sounder (MLS), now in concept development for a potential future mission, is a space-borne heterodyne instrument to measure pressure, temperature, and atmospheric constituents from thermal emission between 120 and 2400 GHz. Previous MLS instruments used pencil-beam antennas sized to resolve N 1 vertical scale height. Current atmospheric models need better horizontal resolution than orbit spacing provides. To meet these needs, a new antenna concept combines the wide scan range of the parabolic torus with unblocked offset Cassegrain optics. The resulting system is diffraction-limited in the vertical plane but extremely astigmatic, with beamwidths 0.13~2.5. Nadir axis symmetry ensures that this Beam AspectRatio (BAR) is invariant over f33' of azimuth. The antenna can feed either an array of receivers or multiplexed low-noise receivers whose FOVs are swept by a small scanning mirror. We describe 3 stages of antenna design: First, using a paraxial-optics method, we choose conic profiles given vertical resolution orbit geometry, then develop the surfaces by nadir axis rotation, matching axisymmetric feeds to the BAR. A ray-trace program validates the design and generates alignment and deformation tolerances. Finally, a physical optics analysis verifies reflector surface currents and radiation patterns.

microwave↗
NASA NTRS2016

Convection from Hemispherical and Conical Model Ice Roughness Elements in Stagnation Region Flows

To improve ice accretion prediction codes, more data regarding ice roughness and its effects on convective heat transfer are required. The Vertical Icing Studies Tunnel (VIST) at NASA Glenn Research was used to model realistic ice roughness in the stagnation region of a NACA 0012 airfoil. In the VIST, a test plate representing the leading 2% chord of the airfoil was subjected to flows of 7.62 m/s (25 ft/s), 12.19 m/s (40 ft/s), and 16.76 m/s (55 ft/s). The test plate was fitted with multiple surfaces or sets of roughness panels, each with a different representation of ice roughness. The sets of roughness panels were constructed using two element distribution patterns that were created based on a laser scan of an iced airfoil acquired in the Icing Research Tunnel at NASA Glenn. For both roughness patterns, surfaces were constructed using plastic hemispherical elements, plastic conical elements, and aluminum conical elements. Infrared surface thermometry data from tests run in the VIST were used to calculate area averaged heat transfer coefficient values. The values from the roughness surfaces were compared to the smooth control surface, showing convective enhancement as high as 400% in some cases. The data gathered during this study will ultimately be used to improve the physical modeling in LEWICE or other ice accretion codes and produce predictions of in-flight ice accretion on aircraft surfaces with greater confidence.

Icing Physics↗
NASA NTRS2011

LIDAR Metrology for Prescription Characterization and Alignment of Large Mirrors

We describe the use of LIDAR, or "laser radar," (LR) as a fast, accurate, and non-contact tool for the measurement of the radius of curvature (RoC) of large mirrors. We report the results of a demonstration of this concept using a commercial laser radar system. We measured the RoC of a 1.4m x 1m spherical mirror with a nominal RoC of 4.6 m with a manufacturing tolerance of 4600mm +/- 6mm. The prescription of the mirror is related to its role as ground support equipment used in the test of part of the James Webb Space Telescope (JWST). The RoC of such a large mirror is not easily measured without contacting the surface. From a position near the center of curvature of the mirror, the LIDAR scanned the mirror surface, sampling it with 1 point per 3.5 sq cm. The measurement consisted of 3983 points and lasted only a few minutes. The laser radar uses the LIDAR signal to provide range, and encoder information from angular azimuth and elevation rotation stages provide the spherical coordinates of a given point. A best-fit to a sphere of the measured points was performed. The resulting RoC was within 20 ppm of the nominal RoC, also showing good agreement with the results of a laser tracker-based, contact metrology. This paper also discusses parameters such as test alignment, scan density, and optical surface type, as well as future possible application for full prescription characterization of aspherical mirrors, including radius, conic, off-axis distance, and aperture.

Eegholm, B.↗
NASA NTRS2012

In-Flight Boundary-Layer Transition on a Large Flat Plate at Supersonic Speeds

A flight experiment was conducted to investigate the pressure distribution, local flow conditions, and boundary-layer transition characteristics on a large flat plate in flight at supersonic speeds up to Mach 2.0. The primary objective of the test was to characterize the local flow field in preparation for future tests of a high Reynolds number natural laminar flow test article. The tests used a F-15B testbed aircraft with a bottom centerline mounted test fixture. A second objective was to determine the boundary-layer transition characteristics on the flat plate and the effectiveness of using a simplified surface coating for future laminar flow flight tests employing infrared thermography. Boundary-layer transition was captured using an onboard infrared imaging system. The infrared imagery was captured in both analog and digital formats. Surface pressures were measured with electronically scanned pressure modules connected to 60 surface-mounted pressure orifices. The local flow field was measured with five 5-hole conical probes mounted near the leading edge of the test fixture. Flow field measurements revealed the local flow characteristics including downwash, sidewash, and local Mach number. Results also indicated that the simplified surface coating did not provide sufficient insulation from the metallic structure, which likely had a substantial effect on boundary-layer transition compared with that of an adiabatic surface. Cold wall conditions were predominant during the acceleration to maximum Mach number, and warm wall conditions were evident during the subsequent deceleration. The infrared imaging system was able to capture shock wave impingement on the surface of the flat plate in addition to indicating laminar-to-turbulent boundary-layer transition.

Banks, Daniel W.↗
NASA NTRS1986

Multibeam Antenna Design and Development for NASA Advanced Communications Technology Satellite (ACTS)

The design of the ACTS multibeam antenna is described, and its performance is evaluated. The multibeam antenna is designed to cover the continential U.S. and provides three fixed spot beams for high burst rate operations and two scanning beams for low burst rate operations. The antenna has one main reflector, a dual polarized subreflector, and two orthogonal feed assemblies. The feed system is to receive a linearly polarized communication signal from 28.9-30.0 GHz and to provide the elevation and azimuth error tracking signals at 29.975 GHz with a 0.01 deg tracking accuracy. The feed system uses a single multiflare conical horn and a multimode coupler to provide a symmetric primary pattern for the communication signal. The sidelobe characteristics of the reflector, and the relation between the sidelobe level and surface distortion are studied. It is noted that the performance measurements for the multibeam antenna correlate well with predictions for secondary patterns and scan characteristics.

Choung, Youn H.↗
NASA NTRS1991

Holographic interferometry at the NASA-Ames Hypervelocity Free-Flight Aerodynamic Facility

A laser holographic interferometer has been designed and developed to improve flow visualization for models in free-flight at high velocities and low freestream static pressures. Of special interest is the flow structure due to high-temperature effects in the post-shock region of models traveling at hypervelocity. A dual-plate technique with a double-pass, Michelson-type configuration has been incorporated in an existing hypervelocity ballistic range. Holograms of 5-deg blunt conical models traveling at 5 km/sec in air at a freestream static pressure of 0.08 atm have been made. Finite- and infinite-fringe interferograms were reconstructed from the holograms and provided qualitative flowfield results. In addition, a digital scanning technique was also used to produce a 'synthetic' infinite-fringe interferogram from the analysis of an experimental finite-fringe interferogram. A 'synthetic' infinite-fringe interferogram shows detail in the wake region not found in the experimental interferograms.

Tam, Tim C.↗
NASA NTRS2007

Laser Range and Bearing Finder with No Moving Parts

A proposed laser-based instrument would quickly measure the approximate distance and approximate direction to the closest target within its field of view. The instrument would not contain any moving parts and its mode of operation would not entail scanning over of its field of view. Typically, the instrument would be used to locate a target at a distance on the order of meters to kilometers. The instrument would be best suited for use in an uncluttered setting in which the target is the only or, at worst, the closest object in the vicinity; for example, it could be used aboard an aircraft to detect and track another aircraft flying nearby. The proposed instrument would include a conventional time-of-flight or echo-phase-shift laser range finder, but unlike most other range finders, this one would not generate a narrow cylindrical laser beam; instead, it would generate a conical laser beam spanning the field of view. The instrument would also include a quadrant detector, optics to focus the light returning from the target onto the quadrant detector, and circuitry to synchronize the acquisition of the quadrant-detector output with the arrival of laser light returning from the nearest target. A quadrant detector constantly gathers information from the entire field of view, without scanning; its output is a direct measure of the position of the target-return light spot on the focal plane and is thus a measure of the direction to the target. The instrument should be able to operate at a repetition rate high enough to enable it to track a rapidly moving target. Of course, a target that is not sufficiently reflective could not be located by this instrument. Preferably, retroreflectors should be attached to the target to make it sufficiently reflective.

Bryan, Thomas C.↗
NASA NTRS1981

Techniques for low sidelobe, high efficiency offset dual reflector antennas

Antennas with very low sidelobe levels and high aperture efficiencies are employed in satellite communications for both ground and satellite borne systems to reduce microwave interference due to traffic congestion to and from the geostationary satellite orbit. Multiple beam antennas with sidelobes 30 to 40 dB below main beam peaks are required with aperture efficiencies approaching 80%. In the present investigation techniques are presented which make it possible to obtain multibeam patterns with the required characteristics. The considered limited scanned antennas have applications to military and commercial radars as well as to space communications. It is pointed out that offset dual reflector antennas designed according to Japanese tilt criteria offer attractive solutions because optimum aperture distributions can be realized without aperture blocking. Attention is given to ideal aperture distributions, corrugated conical horn design, and subreflector design.

Sletten, C. J.↗
NASA NTRS1982

A study in motion sickness - Saccular hair cells in the adult bullfrog

The bullfrog's saccule were examined using light and scanning electron microscopy. No evidence of a striola was found. Type A hair cells were not only distributed peripherally, but also throughout the central macula, though far less frequently than the dominant type D. Two primary hair cell types were distinguished, which corresponded to the ciliary patterns: type A cilia are associated with short, conical hair cells, and type D cilia are associated with long, cylindrical hair cells. Each displays at least one subtype, which may represent developmental precursors. The otolithic membrane is crisscrossed with tunnels and topped with statoconia.

Cohen, G. M.↗
NASA NTRS1999

Assessment of Localized Deformations in Sand Using X-Ray Computed Tomography

The internal fabric and localized deformation patterns of triaxial sand specimens were investigated using Computed Tomography (CT). Three displacement-controlled, conventional, drained axisymmetric (triaxial) experiments were conducted on dry Ottawa sand specimens at very low effective confining stresses (0.05, 0.52, and 1.30 kPa) in a microgravity environment aboard the Space Shuttle during the NASA STS-79 mission. CT scanning was p'erformed on these flight specimens, as well as on an uncompressed specimen and a specimen tested in a terrestrial laboratory at 1.30 kPa effective confining stress. CT demonstrated high accuracy in detecting specimen inhomogeneity and localization patterns. Formation of deformation patterns is dependent on the effective confining stress and gravity. Multiple symmetrical radial shear bands were observed in the specimens tested in a microgravity environment. In the axial direction, two major conical surfaces were developed. Nonsymmetrical spatial deformation was observed in the 1-G specimen. Analysis tools were developed to quantify the spatial density change. Void ratio variation within and outside the shear bands was calculated and discussed.

Alshibli, Khalid A↗
DOE OSTI2025

Temperature Measurements in Hypersonic Wind Tunnels via Femtosecond Coherent Anti-Stokes Raman Scattering

A femtosecond coherent anti-Stokes Raman scattering (fs CARS) instrument is developed to perform gas-phase thermometry in cold-flow hypersonic wind tunnels. Measurements are reported for Mach 8 and 14 pure-nitrogen flows. The fs CARS instrument includes a 100 fs pump/Stokes pulse and a spectrally narrow probe pulse from a second harmonic bandwidth compressor. Important experimental considerations such as limits on the pump/Stokes pulse energy are discussed. The fs CARS focusing and collimating optics are mounted on a two-axis translation stage system to scan the measurement location during a 30 second wind tunnel run. Single-laser-shot rotational CARS spectra are recorded at the laser repetition rate of 1 kHz in the wind tunnel freestream and near simple cone models. Spectral fitting is used to determine quantitative gas temperatures. Freestream temperatures at Mach 8 and 14 spanned ranges of 40–75 and 35–50 K, respectively, depending on tunnel operating conditions. Temperature variations across the central 100 mm span of the wind tunnel were quantified. Measured temperature jumps across conical bow shocks from various models varied by less than 1% from predicted values. Hypersonic boundary layer measurements were demonstrated. In conclusion, these measurements illustrate the utility and robustness of this instrument for the study of complex fluid flow phenomena in challenging ground test facilities.

Aerodynamics↗
NASA NTRS1971

An orbiting multispectral scanner for overland and oceanographic applications.

Description of the major features of a multispectral scanner designed to perform overland and oceanographic surveys from space. The instrument uses an image plane conical scanner and contains independent spectrometers for land and ocean applications. The overland spectrometer has a spatial resolution of 200 ft and has six spectral bands in the atmospheric windows between 0.5 and 2.4 microns. The oceanographic spectrometer has a spatial resolution of 1200 ft and possesses 24 spectral bands equally spaced and in registration over the wavelength range from 0.4 to 0.8 micron. A thermal band of 600-ft resolution is used with a spectral range from 10.5 to 12.6 microns. The swath width of the scan is 100 nautical miles from an altitude of 500 nautical miles. The system has two modes of operation which are selectable by ground command. The six bands of overland data plus the thermal band data can be transmitted, or the 24 bands of oceanographic data plus data from two of the overland bands and the thermal band can be transmitted. The performance is described by the minimum detectable reflectance difference and the effects of sun angle and target reflectivity variations are discussed. The sensitivity is related to the variation of the ocean reflectivity in the presence of chlorophyll and to typical agricultural targets.

Peacock, K.↗
DOE OSTI2025

Orientation-Dependent Nanomechanical Behavior of Pentaerythritol Tetranitrate as Probed by Multiple Nanoindentation Tip Geometries

Nanoindentation can be leveraged to aid in the high fidelity modeling of dislocation mediated plasticity in pentaerythritol tetranitrate (PETN), an anisotropic energetic molecular crystal. Moreover, nanoindentation tip parameters such as tip geometry, size, and degree of acuity can be utilized to target anisotropic behavior. In this work, nanoindentation was conducted across a range of orientations on the (110) face of PETN to characterize resultant yield behavior, mechanical property measurements, and resultant slip behavior and fracture initiation. Three different indentation tips were utilized: a 3-sided pyramidal Berkovich tip, a 4-sided high aspect ratio Knoop tip, and a 90° conical tip. Ultimately, indenter tip radius was documented to impact yield behavior, whereas tip geometry affected larger scale processes such as slip, and tip acuity was the dominating factor that led to fracture. The axisymmetric conical tip, serving as a baseline, showed the least amount of variation in mechanical property measurements but also the largest distribution of maximum shear stress at which initial yielding occurred. Its high degree of acuity, however, was more prone to induce fracture at higher loads. The Knoop tip was shown to be suitable for average measurements, but also for elucidation of certain anisotropic features. A distinctly higher perceived hardness at 45° was measured with the Knoop tip, indicating less dislocation motion in that direction also observed in this work via scanning probe microscopy. Lastly, the commonly used Berkovich tip was a good compromise whereby it provided a representative volume element describing the average behavior of the material. These results can be utilized to target desired anisotropic behavior in a wider range of molecular crystals, as well as to inform theoretical considerations for dislocation mediated plasticity in PETN.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Laser supported detonation wave source of atomic oxygen for aerospace material testing

A pulsed high-flux source of nearly monoenergetic atomic oxygen was developed to perform accelerated erosion testing of spacecraft materials in a simulated low-earth orbit (LEO) environment. Molecular oxygen is introduced into an evacuated conical expansion nozzle at several atmospheres pressure through a pulsed molecular beam valve. A laser-induced breakdown is generated in the nozzle throat by a pulsed CO2 TEA laser. The resulting plasma is heated by the ensuing laser-supported detonation wave, and then it rapidly expands and cools. An atomic oxygen beam is generated with fluxes above 10 to the 18th atoms per pulse at 8 + or - 1.6 km/s with an ion content below 1 percent for LEO testing. Materials testing yielded the same surface oxygen enrichment in polyethylene samples as observed on the STS mission, and scanning electron micrographs of the irradiated polymer surfaces showed an erosion morphology similar to that obtained on low earth orbit.

Krech, Robert H.↗
NASA NTRS1995

Fabrication of the Advanced X-ray Astrophysics Facility (AXAF) Optics: A Deterministic, Precision Engineering Approach to Optical Fabrication

The mirror assembly of the AXAF observatory consists of four concentric, confocal, Wolter type 1 telescopes. Each telescope includes two conical grazing incidence mirrors, a paraboloid followed by a hyperboloid. Fabrication of these state-or-the-art optics is now complete, with predicted performance that surpasses the goals of the program. The fabrication of these optics, whose size and requirements exceed those of any previous x-ray mirrors, presented a challenging task requiring the use of precision engineering in many different forms. Virtually all of the equipment used for this effort required precision engineering. Accurate metrology required deterministic support of the mirrors in order to model the gravity distortions which will not be present on orbit. The primary axial instrument, known as the Precision Metrology Station (PMS), was a unique scanning Fizeau interferometer. After metrology was complete, the optics were placed in specially designed Glass Support Fixtures (GSF's) for installation on the Automated Cylindrical Grinder/Polishers (ACG/P's). The GSF's were custom molded for each mirror element to match the shape of the outer surface to minimize distortions of the inner surface. The final performance of the telescope is expected to far exceed the original goals and expectations of the program.

Gordon, T. E.↗
NASA NTRS2012

GPM Mission Overview and U.S. Science Status

The Global Precipitation Measurement (GPM) Mission is an international satellite mission to unify and advance precipitation measurements from a constellation of research and operational sensors to provide "next-generation" precipitation products [1-2]. Water is fundamental to life on Earth. Knowing where and how much rain and snow falls globally is vital to understanding how weather and climate impact both our environment and Earth's water and energy cycles, including effects on agriculture, fresh water availability, and responses to natural disasters. Since rainfall and snowfall vary greatly from place to place and over time, satellites can provide more uniform observations of rain and snow around the globe than ground instruments, especially in areas where surface measurements are difficult. Relative to current global rainfall products, GPM data products will be characterized by: (l) more accurate instantaneous precipitation measurements (especially for light rain and cold-season solid precipitation), (2) more frequent sampling by an expanded constellation of domestic and international microwave radiometers including operational humidity sounders, (3) intercalibrated microwave brightness temperatures from constellation radiometers within a unified framework, and (4) physical-based precipitation retrievals from constellation radiometers using a common a priori cloud/hydrometeor database derived from GPM Core sensor measurements. The cornerstone of the GPM mission is the deployment of a Core Observatory in a unique 65 non-Sun-synchronous orbit to serve as a physics observatory and a reference standard to unify precipitation measurements by a constellation of dedicated and operational passive microwave sensors. The design of the GPM Core Observatory is an advancement of the Tropical Rainfall Measuring Mission (TRMM)'s highly successful rain-sensing package. The Core Observatory will carry a Ku/Ka-band Dual-frequency Precipitation Radar (DPR) and a multichannel (l0-183 GHz) GPM Microwave Radiometer (GMI). Since light rain and falling snow account for a significant fraction of precipitation occurrence in middle and high latitudes, the GPM instruments extend the capabilities of the TRMM sensors to detect falling snow, measure light rain, and provide, for the first time, quantitative estimates of microphysical properties of precipitation particles. The combined use of DPR and GMI measurements will place greater constraints on possible solutions to radiometer retrievals to improve the accuracy and consistency of precipitation retrievals from all constellation radiometers. The GMI uses 13 different microwave channels to observe energy from the different types of precipitation through clouds for estimating everything from heavy to light rain and for detecting falling snow. As the satellite passes over Earth, the GMI constantly scans a region 885 kilometers across. The Ball Aerospace and Technology Corporation built the GMI under contract with NASA Goddard Space Flight Center. The DPR provides three-dimensional information about precipitation particles derived from reflected energy by these particles at different heights within the cloud system. The two frequencies of the DPR also allow the radar to infer the sizes of precipitation particles and offer insights into a storm's physical characteristics. The Ka-band frequen~y scans across a region of 125 kilometers and is nested within the wider scan of the Ku-band frequency of 245 kilometers. The Japan Aerospace and Exploration Agency (JAXA) and Japan's National Institute of Information and Communications Technology (NICT) built the DPR. The Core Observatory satellite will fly at an altitude of 253 miles (407 kilometers) in a non-Sun-synchronous orbit that covers the Earth from 65 S to 65 N - from about the Antarctic Circle to the Arctic Circle. The GPM Core Observatory is being developed and tested at NASA Goddard Space Flight Center. Once complete, a Japanese H-lIA rocket will carry thPM Core Observatory into orbit from Tanegashima Island, Japan in 2014. The GPM constellation is envisioned to comprise 8 or more microwave sensors provided by partners, including both conical imagers and cross-track sounders. GPM is currently a partnership between NASA and the Japan Aerospace Exploration Agency (JAXA). Additional partnerships are under development to include microwave radiometers on the French-Indian Megha-Tropiques satellite and U.S. Defense Meteorological Satellite Program (DMSP) satellites, as well as humidity sounders or precipitation sensors on operational satellites such as the National Polar-orbiting Operational Environmental Satellite System (NPOESS) Preparatory Project (NPP), NOAA-NASA Joint Polar Satellite System (JPSS) satellites, European MetOp satellites, and DMSP follow-on sensors. In addition, data from Chinese and Russian microwave radiometers may be available through international cooperation under the auspices of the Committee on Earth Observation Satellites (CEOS) and Group on Earth Observations (GEO). GPM's next-generation global precipitation data will lead to scientific advances and societal benefits in the following areas: (1) Improved knowledge of the Earth's water cycle and its link to climate change (2) New insights into precipitation microphysics, storm structures and large-scale atmospheric processes (3) Better understanding of climate sensitivity and feedback processes (4) Extended capabilities in monitoring and predicting hurricanes and other extreme weather events (5) Improved forecasting capabilities for natural hazards, including floods, droughts and landslides. (6) Enhanced numerical prediction skills for weather and climate (7) Better agricultural crop forecasting and monitoring of freshwater resources. An overview of the GPM mission concept and science activities in the United States, together with an update on international collaborations in radiometer intercalibration and ground validation, will be presented.

Hou, Arthur Y.↗
NASA NTRS2000

Laser Brazing of High Temperature Braze Alloy

The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.

Gao, Y. P.↗